Hi,

I've been doing some milling in aluminium with my DIY-CNC router. The router is a 1.2x0.6meter mill with a 2.2kW water-cooled spindle. The axes are driven by quite powerful Nema23 380oz/in steppers.

It's very hard to know the correct feed, and the correct spindle speed when milling. Also it's hard to know how deep I can cut . So when Im doing it wrong, the flutes gets filled with aluminium and I have to pause to remove it.

So here is my questions for aluminium milling:
1: Is there any rule or guidelines to how deep one should cut (as long as the spindle is up for it)?
2: Is there a way of calculating the correct feed and spindle-RPM?
3: When the flutes get packed, should I turn up or down the feed or the spindle RPM?
4: Is there such a thing as too much cooling liquid (except for the mess)?


As for point 4: Im now having cooling liquid on a spray flask, and spraying from time to time (maybe every 10-15 seconds). Is this OK, or I'm I using too little?


Thanks for any and all answers!